EP2249417A2 - Sekundärbatterie mit wasserfreiem Elektrolyt - Google Patents

Sekundärbatterie mit wasserfreiem Elektrolyt Download PDF

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Publication number
EP2249417A2
EP2249417A2 EP10008773A EP10008773A EP2249417A2 EP 2249417 A2 EP2249417 A2 EP 2249417A2 EP 10008773 A EP10008773 A EP 10008773A EP 10008773 A EP10008773 A EP 10008773A EP 2249417 A2 EP2249417 A2 EP 2249417A2
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EP
European Patent Office
Prior art keywords
positive electrode
active material
grooves
electrode active
material layer
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Withdrawn
Application number
EP10008773A
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English (en)
French (fr)
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EP2249417A3 (de
Inventor
Akira Yajima
Hirotaka Hayashida
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Toshiba Corp
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Toshiba Corp
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Publication of EP2249417A2 publication Critical patent/EP2249417A2/de
Publication of EP2249417A3 publication Critical patent/EP2249417A3/de
Withdrawn legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/04—Construction or manufacture in general
    • H01M10/0431—Cells with wound or folded electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/04—Construction or manufacture in general
    • H01M10/0436—Small-sized flat cells or batteries for portable equipment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H01M4/0404—Methods of deposition of the material by coating on electrode collectors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/043—Processes of manufacture in general involving compressing or compaction
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M2004/021—Physical characteristics, e.g. porosity, surface area
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M2004/025—Electrodes composed of, or comprising, active material with shapes other than plane or cylindrical
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
    • H01M2004/028—Positive electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/131—Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention relates to a nonaqueous electrolyte secondary battery.
  • a lithium ion secondary battery As a lithium ion secondary battery, a battery having an arrangement using a lithium composite oxide as a positive electrode active material and a carbonaceous material, which allows doping and undoping of lithium ions, as a negative electrode active material is known.
  • This lithium ion secondary battery is expected to be used as a superior power supply because the battery is small and light, the voltage of a single cell is high, and a high energy density can be obtained.
  • the conventional lithium ion secondary battery realizes a high energy density by using highly densified positive and negative electrodes.
  • the initial characteristics, particularly, the discharge characteristics when a large electric current is discharged are unstable, and the charge/discharge cycle characteristics deteriorate.
  • Jpn. Pat. Appln. KOKAI Publication No. 11-86870 discloses a positive electrode in which linear grooves are formed in a depolarizing mix layer formed on the main surface of a current collector and containing a material which participates in an electrochemical reaction, such that the two ends of each groove open at the edges of the depolarizing mix layer.
  • the principal object of this invention is, if the internal temperature of the battery rises due to a shortcircuit or an abnormal electric current and the electrode material or electrolyte gasifies, to rapidly move the gas outside the electrode through the grooves. A reduction in liquid injection time is also described as a secondary effect of the grooves.
  • this invention does not mention, e.g., the selection of the form of the grooves in relation to the battery characteristics such as the large-current discharge characteristics or cycle life characteristics.
  • the present inventors made extensive studies on factors by which the initial characteristics, particularly, the discharge characteristics when a large electric current is discharged become unstable in a high-energy-density, nonaqueous electrolyte secondary battery including high-density positive and negative electrodes, i.e., low-void positive and negative electrodes.
  • the present inventors have found that there is a large difference between the values of permeability of a nonaqueous electrolyte to the high-density positive electrode and the high-density negative electrode (more specifically, the permeation speed of an electrolyte at the negative electrode is much higher than that of the electrolyte at the positive electrode), and this causes a nonuniform nonaqueous electrolyte permeation distribution between the positive and negative electrodes.
  • the present inventors also made extensive studies on deterioration of the charge/discharge cycle characteristics of a high-energy-density, nonaqueous electrolyte secondary battery including high-density positive and negative electrodes, i.e., low-void positive and negative electrodes.
  • the present inventors have found that the negative electrode has a volume change larger than that of the positive electrode during a charge/discharge cycle and hence easily swells, so the electrolyte often moves toward the negative electrode when the charge/discharge cycle is repeated, and this prevents sufficient supply of the electrolyte to the positive electrode at the charge/discharge cycle progresses.
  • the present inventors made further extensive studies, and made it possible, by defining the specific surface area per unit area of a positive electrode active material of the positive electrode to 0.5 to 1.0 times the specific surface area per unit area of a negative electrode active material of the negative electrode which opposes the positive electrode with a separator sandwiched between them, to balance the speeds of permeation of the nonaqueous electrolyte to the positive and negative electrodes, to make uniform the nonaqueous electrolyte permeation distribution between the positive and negative electrodes, and to impregnate the positive electrode with a sufficient amount of the nonaqueous electrolyte, when an electrode assembly having the positive and negative electrodes and the separator was accommodated in an outer packaging member such as a metal can, and the nonaqueous electrolyte was supplied to the outer packaging member.
  • the present inventors could obtain a high-energy-density, nonaqueous electrolyte secondary battery in which the initial characteristics, particularly, the charge characteristics when a large electric current was discharged stabilized and the charge/discharge cycle characteristics improved, and completed the present invention.
  • the present inventors made it possible, by forming grooves having a specific form in a positive electrode active material formation surface of a positive electrode, to balance the speeds of permeation of a nonaqueous electrolyte to the positive and negative electrodes, to make uniform the nonaqueous electrolyte permeation distribution between the positive and negative electrodes, and to impregnate the positive electrode with a sufficient amount of the nonaqueous electrolyte, when an electrode assembly having the positive and negative electrodes and the separator was accommodated in an outer packaging member such as a metal can, and the nonaqueous electrolyte was supplied to the outer packaging member.
  • the present inventors could obtain a high-energy-density, nonaqueous electrolyte secondary battery in which the initial characteristics, particularly, the charge characteristics when a large electric current was discharged stabilized and the charge/discharge cycle characteristics improved, and completed the present invention.
  • a nonaqueous electrolyte secondary battery comprising an electrode assembly having a high-density positive electrode in which a positive electrode active material layer is formed on at least one surface of a positive electrode current collector, a high-density negative electrode in which a negative electrode active material layer is formed on at least one surface of a negative electrode current collector, and a separator interposed between the positive and negative electrodes, and having a structure in which the electrode assembly is impregnated with a nonaqueous electrolyte, wherein a specific surface area per unit area of the positive electrode active material layer of the positive electrode is 0.5 to 1.0 times a specific surface area per unit area of the negative electrode active material layer of the negative electrode which opposes the positive electrode with the separator sandwiched between them.
  • a nonaqueous electrolyte secondary battery comprising an electrode assembly having a high-density positive electrode in which a positive electrode active material layer is formed on at least one surface of a positive electrode current collector, a high-density negative electrode in which a negative electrode active material layer is formed on at least one surface of a negative electrode current collector, and a separator interposed between the positive and negative electrodes, and having a structure in which the electrode assembly is impregnated with a nonaqueous electrolyte, wherein a plurality of grooves are formed in a formation surface of the positive electrode active material layer of the positive electrode, such that end portions of the grooves open at edges of the positive electrode active material layer, and the grooves are formed at a frequency of 1 to 10 grooves per mm of the positive electrode active material layer, and a sectional area of the grooves account for a ratio of 1 to 20% of a sectional area of the positive electrode active material layer.
  • a nonaqueous electrolyte secondary battery comprising an electrode assembly having a high-density positive electrode in which a positive electrode active material layer is formed on at least one surface of a positive electrode current collector, a high-density negative electrode in which a negative electrode active material layer is formed on at least one surface of a negative electrode current collector, and a separator interposed between the positive and negative electrodes, and having a structure in which the electrode assembly is impregnated with a nonaqueous electrolyte, wherein a specific surface area per unit area of the positive electrode active material layer of the positive electrode is 0.5 to 1.0 times a specific surface area per unit area of the negative electrode active material layer of the negative electrode which opposes the positive electrode with the separator sandwiched therebetween.
  • the high-density positive electrode may have a density of not less than 3.0 g/cm 3
  • the high-density negative electrode has a density of not less than 1.3 g/cm 3 .
  • This nonaqueous electrolyte secondary battery includes an electrode assembly having a high-density positive electrode obtained by forming a positive electrode active material layer on at least one surface of a positive electrode current collector, a high-density negative electrode obtained by forming a negative electrode active material on at least one surface of a negative electrode current collector, and a separator interposed between the positive and negative electrodes.
  • the electrode assembly and a nonaqueous electrolyte are accommodated in an outer packaging member.
  • the high-density positive electrode, high-density negative electrode, separator, and nonaqueous electrolyte will be explained below.
  • high-density positive electrode is meant that the electrode density is 3.0 g/cm 3 or more (preferably, 3.1 g/cm 3 to 3.5 g/cm 3 ).
  • the high-density positive electrode is formed by, e.g., the following methods.
  • the positive electrode active material is not particularly limited as long as it can easily absorb and desorb lithium ions during charge and discharge. More specifically, lithium cobaltate, lithium nickelate, lithium manganate, lithium-containing iron oxide, or vanadium oxide containing lithium is used as the positive electrode active material, and the positive electrode active material is preferably made of any of these composite oxides or their mixture.
  • the positive electrode active material can also contain, e.g., manganese dioxide, titanium disulfide, or molybdenum disulfide.
  • the positive electrode active material is preferably a particulate material having an average particle size of 2 to 20 ⁇ m, when the adhesion to a substrate during the manufacture of the electrode and the electrochemical characteristics are taken into consideration.
  • Examples of the conductive material are acetylene black, carbon black, and graphite.
  • binder it is possible to use, e.g., polyvinylidene fluoride (PVdF), a vinylidene fluoride-propylene hexafluoride copolymer, a vinylidene fluoride-tetrafluoroethylene-propylene hexafluoride ternary copolymer, a vinylidene fluoride-pentafluoropropylene copolymer, a vinylidene fluoride-chlorotrifluoroethylene copolymer, a tetrafluoroethylene-purple fluoroalkylvinylether (PFA)-vinylidene fluoride ternary copolymer, a tetrafluoroethylene-ethylene-vinylidene fluoride ternary copolymer, a chlorotrifluoroethylene-vinylidene fluoride copolymer, a chlorotrifluoroethylene-ethylene-vinylidene fluoride cop
  • the current collector it is possible to use, e.g., aluminum foil, stainless steel foil, or titanium foil.
  • the current collector is most preferably aluminum foil when tensile strength, electrochemical stability, flexibility during winding, and the like are taken into consideration.
  • the thickness of the foil is preferably 10 to 30 ⁇ m.
  • the thickness of the foil is less than 10 ⁇ m, not only can the strength as an electrode not be obtained any longer, but also strain introduced by expansion and contraction of the active material caused by a charge/discharge reaction cannot be relaxed any longer, and this may break the positive electrode.
  • the thickness of the foil exceeds 30 ⁇ m, not only the filling amount of the active material is reduced, but also the flexibility of the positive electrode is lost, and this may allow easy occurrence of an internal short circuit.
  • high-density negative electrode is meant that the electrode density is 1.3 g/cm 3 or more (preferably, 1.35 g/cm 3 to 1.60 g/cm 3 ).
  • the high-density negative electrode is formed by, e.g., the following methods.
  • An example of the negative electrode active material is a compound which absorbs and desorbs lithium ions.
  • the compound which absorbs and desorbs lithium ions are conductive polymers capable of doping lithium ions, such as polyacetal, polyacetylene, and polypyrrol, carbon materials capable of doping lithium ions, such as coke, carbon fibers, graphite, mesophase frequency-based carbon, a pyrolytic gas-phase carbon substance, and a resin sintered product, and chalcogen compounds such as titanium disulfide, molybdenum disulfide, and niobium selenide.
  • the forms of the carbon materials are a graphite-based carbon material, a carbon material containing both a graphite crystal portion and amorphous portion, and a carbon material having a stacked structure in which a crystal layer is irregular.
  • binder it is possible to use, e.g., polytetrafluoroethylene, polyvinylidene fluoride, an ethylene-propylene-diene copolymer, styrene-butadiene rubber, or carboxymethylcellulose.
  • metal foil it is possible to use copper foil, nickel foil, or stainless steel foil.
  • This separator is formed from a porous sheet or the like.
  • a porous sheet a porous film, unwoven fabric, or the like can be used.
  • the porous sheet is preferably made of at least one type of material selected from, e.g., polyolefin and cellulose.
  • polyolefin examples include polyethylene, polypropylene, an ethylene-propylene copolymer, and an ethylene-butene copolymer.
  • a porous film made of one or both of polyethylene and polypropylene can improve the safety of a secondary battery.
  • This nonaqueous electrolyte can improve the ionic conductivity.
  • This nonaqueous electrolyte is prepared by, e.g., dissolving a lithium salt in a nonaqueous solvent.
  • nonaqueous solvent examples include propylene carbonate (PC), ethylene carbonate (EC), dimethyl carbonate (DMC), diethyl carbonate (DEC), 1,2-dimethoxyethane (DME), ⁇ -butyrolactone ( ⁇ -BL), tetrahydrofuran (THF), 2-methyltetrahydrofuran (2-MeTHF), 1,3-dioxolane, 1,3-dimethoxypropane, and vinylene carbonate (VC).
  • PC propylene carbonate
  • EC ethylene carbonate
  • DMC dimethyl carbonate
  • DEC diethyl carbonate
  • DME 1,2-dimethoxyethane
  • ⁇ -BL ⁇ -butyrolactone
  • THF tetrahydrofuran
  • 2-MeTHF 2-methyltetrahydrofuran
  • 1,3-dioxolane 1,3-dimethoxypropane
  • vinylene carbonate vinylene carbonate
  • nonaqueous solvents (1) a nonaqueous solvent containing EC and ⁇ -BL, (2) a nonaqueous solvent containing EC, ⁇ -BL, and VC, (3) a nonaqueous solvent containing EC, ⁇ -BL, and PC, and (4) a nonaqueous solvent containing EC, ⁇ -BL, PC, and VC are preferable.
  • Nonaqueous solvents 2 and 4 are particularly preferable.
  • the volume ratio of ⁇ -BL is preferably 30 vol% or more and 90 vol% or less.
  • lithium salt electrolyte
  • lithium perchlorate LiClO 4
  • lithium borofluoride LiBF 4
  • lithium arsenic hexafluoride LiAsF 6
  • lithium phosphate hexafluoride LiPF 6
  • lithium trifluoromethasulfonate LiCF 3 SO 3
  • lithium aluminum tetrachloride LiAlCl 4
  • lithium salt it is possible to use one type or two or more types selected from the types described above.
  • lithium borofluoride (LiBF 4 ) is preferable because the generation of gas during initial charging can be suppressed.
  • the specific surface area per unit area of a positive electrode active material layer of the positive electrode is 0.5 to 1.0 times the specific surface area per unit area of a negative electrode active material layer of the negative electrode which opposes the positive electrode with the separate sandwiched between them.
  • the effect of drawing the nonaqueous electrolyte to the positive electrode becomes unsatisfactory when the electrode assembly having the positive electrode, negative electrode, and separator is accommodated in an outer packaging member, e.g., an outer packaging member made up of a metal can and covers, and the nonaqueous electrolyte is supplied to the outer packaging member.
  • an outer packaging member e.g., an outer packaging member made up of a metal can and covers
  • the nonaqueous electrolyte is supplied to the outer packaging member.
  • the nonaqueous electrolyte permeation distribution becomes nonuniform between the positive and negative electrodes.
  • the specific surface area per unit area of the positive electrode active material layer of the positive electrode exceeds 1.0 times that of the negative electrode active material layer of the negative electrode, the strength of the positive electrode active material layer is reduced, and the positive electrode active material layer peels off from the current collector.
  • the specific surface area per unit area of the positive electrode active material layer of the positive electrode is more preferably 0.6 to 0.9 times the specific surface area per unit area of the negative electrode active material layer of the negative electrode.
  • the positive electrode meeting the relationship between the specific surface areas of the positive and negative electrodes can take a form in which a plurality of circular or rectangular embosses are formed in the formation surface of the positive electrode active material layer, in addition to a form to be described later in which grooves to be described later are formed in the formation surface of the positive electrode active material layer.
  • Examples of the nonaqueous electrolyte secondary battery according to the present invention are a cylindrical type shown in FIG. 1 , a square type shown in FIG. 2 , and a thin type shown in FIGS. 3 and 4 to be explained below.
  • a closed-end, cylindrical outer packaging can 11 which is made of a metal such as aluminum or stainless steel and also functions as a negative terminal has an insulating plate 12 on its bottom portion.
  • An electrode assembly 16 obtained by spirally winding a positive electrode 13 and negative electrode 14 is contained in the outer packaging can 11.
  • a nonaqueous electrolyte is injected from an opening into the outer packaging can 1 containing the electrode assembly 16.
  • An insulating plate 17 is so placed as to be positioned above the electrode assembly 16 in the outer packaging can 11.
  • a sealing plate 19 made of an insulating material is airtightly attached to the opening of the outer packaging can 11 by caulking.
  • a positive terminal 18 is fitted near the center of the sealing plate 19. That end face of the positive terminal 18, which is positioned in the outer packaging can 11 is connected to the positive electrode 13 via a positive electrode tab 20.
  • the outer packaging can 11 which also functions as a negative terminal is connected to the negative electrode 14 via a negative electrode tab, and the bottom portion of the outer packaging can 11 is used as a negative terminal.
  • a closed-end, rectangular cylindrical outer packaging can 21 made of a metal such as aluminum shown in FIG. 2 also functions as, e.g., a positive terminal, and an insulating film 22 is formed on the inner surface of its bottom portion.
  • An electrode assembly 23 is contained in the outer packaging can 21. Note that if the outer packaging can 21 is made of stainless steel or iron, it also functions as a negative terminal.
  • the electrode assembly 23 is formed by spirally winding a negative electrode 24, separator 25, and positive electrode 26 such that the positive electrode 26 is positioned on the outermost circumference, and press-molding the resultant structure into a flat shape.
  • a spacer 27 made of, e.g., a synthetic resin and having a lead extracting hole near its center is placed on the electrode assembly 23 in the outer packaging can 21.
  • a metal cover 28 is airtightly joined to the upper-end opening of the outer packaging can 21 by, e.g., laser welding.
  • An extraction hole 29 for a negative terminal is formed near the center of the cover 28.
  • a negative terminal 30 is hermetically sealed to the hole 29 of the cover 28 via an insulating material 31 made of glass or resin.
  • a lead 32 is connected to the lower end face of the negative terminal 30, and the other end of the lead 32 is connected to the negative electrode 24 of the electrode assembly 23.
  • a liquid injection hole (not shown) is formed in that portion of the cover 28, which is separated from the extraction hole 29, and a nonaqueous electrolyte is injected into the outer packaging can 21 through this liquid injection hole. Note that the liquid injection hole is sealed by a sealing cover (not shown) after the nonaqueous electrolyte is injected.
  • Upper insulating paper 33 and lower insulating paper 34 cover the entire outer surface of the cover 28 and the bottom surface of the outer packaging can 21, respectively.
  • a jacket tube 35 is so placed as to extend from the side surface of the outer packaging can 21 to the peripheries of the insulating papers 33 and 34 on the upper and lower surfaces, and fixes the upper insulating paper 33 and lower insulating paper 34 to the outer packaging can 21.
  • an electrode assembly 41 has, e.g., a flat rectangular shape obtained by spirally winding a positive electrode 44 having positive electrode active material layers 42 carried on the two surfaces of a current collector 43, a separator 45, a negative electrode 48 having negative electrode active material layers 46 carried on the two surfaces of a current collector 47, and a separator 45, and molding the resultant structure.
  • External lead terminals 49 and 50 connected to the positive electrode 44 and negative electrode 48, respectively, extend outside from the same side surface of the electrode assembly 41.
  • the electrode assembly 41 is enclosed in, e.g., a cup 52 of a cup-like jacket film 51 folded in two, such that the folded portion is positioned on the side surface opposite to the side surface from which the external lead terminals 49 and 50 extend.
  • the jacket film 51 has a structure in which a sealant film 53 positioned on the inner surface side, an aluminum or aluminum alloy foil 54, and a rigid organic resin film 55 are stacked in this order.
  • Those three side portions, except for the folded portion, of the jacket film 51, which correspond to two long side surfaces and one short side surface of the electrode assembly 41 have seal portions 56a, 56b, and 56c extended in the horizontal direction by thermally sealing the sealant films 53, and the seal portions 56a, 56b, and 56c seal the electrode assembly 41.
  • a nonaqueous electrolyte is contained by impregnation in the electrode assembly 41 and in the jacket film 51 sealed by the seal portions 56a, 56b, and 56c.
  • the jacket film is not limited to a cut type, and can also be a pillow type or a pouch type.
  • the nonaqueous electrolyte secondary battery of the first embodiment according to the present invention includes an electrode assembly having a high-density positive electrode having a positive electrode active material layer formed on at least one surface of a positive electrode current collector, a high-density negative electrode having a negative electrode active material layer formed on at least one surface of a negative electrode current collector, and a separator interposed between the positive and negative electrodes, has a structure in which the electrode assembly is impregnated with a nonaqueous electrolyte, and has an arrangement in which the specific surface area per unit area of the positive electrode active material layer of the positive electrode is 0.5 to 1.0 times the specific surface area per unit area of the negative electrode active material layer of the negative electrode. With this arrangement, it is possible to obtain a high-energy-density, nonaqueous electrolyte secondary battery in which the initial characteristics, particularly, the discharge characteristics when a large electric current is discharged stabilize, and the charge/discharge cycle characteristics improve.
  • This nonaqueous electrolyte secondary battery includes an electrode assembly having a high-density positive electrode obtained by forming a positive electrode active material layer on at least one surface of a positive electrode current collector, a high-density negative electrode obtained by forming a negative electrode active material layer on at least one surface of a negative electrode current collector, and a separator interposed between the positive and negative electrodes.
  • This electrode assembly is impregnated with a nonaqueous electrolyte.
  • the electrode assembly and nonaqueous electrolyte are contained in an outer packaging member.
  • the same high-density positive electrode, high-density negative electrode, separator, and nonaqueous electrolyte as explained in the first embodiment can be used.
  • a plurality of grooves are formed in the formation surface of the positive electrode active material such that the end portions of these grooves open at the edges of the positive electrode active material layer. These grooves are formed at a frequency of 1 to 10 grooves per mm as a length in the positive electrode active material layer, and the sectional area of the grooves accounts for a ratio of 1 to 20% of the sectional area of the positive electrode active material layer.
  • the plurality of grooves are formed by, e.g., passing the positive electrode having the positive electrode active material between a pair of rolls at least one of which is an engraved emboss roll.
  • the number of the plurality of grooves formed in the positive electrode active material layer is less than 1 per mm as a length, the effect of drawing the nonaqueous electrolyte to the positive electrode becomes unsatisfactory, and the nonaqueous electrolyte permeation distribution becomes nonuniform between the positive and negative electrodes.
  • the number of the plurality of grooves formed in the positive electrode active material layer exceeds 10 per mm as a length, the strength of the positive electrode is reduced, and the positive electrode active material layer peels off from the current collector.
  • the number of plurality of grooves formed in the positive electrode active material layer is more preferably 4 to 8 per mm as a length.
  • sectional area of the plurality of grooves is less than 1% of the sectional area of the positive electrode active material layer, the effect of drawing the nonaqueous electrolyte to the positive electrode becomes unsatisfactory, and the nonaqueous electrolyte permeation distribution becomes nonuniform between the positive and negative electrodes.
  • the sectional area of the plurality of grooves exceeds 20% of the sectional area of the positive electrode active material, the strength of the positive electrode is reduced, and the positive electrode active material layer peels off from the current collector.
  • the sectional area of the plurality of grooves is more preferably 2 to 15 % of the sectional area of the positive electrode active material.
  • the sectional shape of the groove is not particularly limited, and examples are an inverted trapezoidal shape, V-shape, and U-shape. However, to advance permeation of the electrolyte from the surface of the positive electrode active material layer, the sectional shape of the groove is preferably an inverted trapezoidal shape.
  • the groove can be a linear groove or curved groove. More specifically, as shown in FIG. 5 , a plurality of linear grooves 3 having an inverted trapezoidal sectional shape are formed in a positive electrode active material layer 2 carried on one surface of a current collector 1. Alternatively, as shown in FIG. 6 , a plurality of curved grooves 4 having an inverted trapezoidal sectional shape are formed in a positive electrode active material layer 2 carried on one surface of a current collector 1.
  • the curved grooves 4 having an inverted trapezoidal sectional shape in the positive electrode active material layer 2 as shown in FIG. 6 .
  • linear or curved grooves are preferably inclined in the longitudinal direction of the positive electrode. More specifically, as shown in FIG. 7 , a plurality of linear grooves 5 having an inverted trapezoidal sectional shape are formed in a positive electrode active material layer 2 carried on one surface of a current collector 1, so as to be inclined to make an angle ⁇ with the longitudinal direction of the current collector 1.
  • This inclination angle ( ⁇ ) is preferably 45 to 75°.
  • FIG. 8 it is also possible to carry positive electrode active material layers 2a and 2b on the upper and lower surfaces of a current collector 1, and form a plurality of linear grooves 5a and 5b having an inverted trapezoidal sectional shape in the positive electrode active material layers 2a and 2b, respectively, such that these grooves are inclined to the longitudinal direction of the current collector 1.
  • the plurality of grooves are thus formed in the positive electrode active material layers on the upper and lower surfaces of the current collector 1 so as to be inclined to the longitudinal direction of the current collector, as shown in FIG.
  • a plurality of linear grooves 5a and 5b having an inverted trapezoidal sectional shape are preferably formed in positive electrode active material layers 2a and 2b, respectively, on the upper and lower surfaces of a current collector 1, so as to cross each other when seen through one surface.
  • Examples of the nonaqueous electrolyte secondary battery according to the present invention are the cylindrical type shown in FIG. 1 , the square type shown in FIG. 2 , and the thin type shown in FIGS. 3 and 4 mentioned earlier.
  • the nonaqueous electrolyte secondary battery of the second embodiment according to the present invention includes an electrode assembly having a high-density positive electrode having a positive electrode active material layer formed on at least one surface of a positive electrode current collector, a high-density negative electrode having a negative electrode active material layer formed on at least one surface of a negative electrode current collector, and a separator interposed between the positive and negative electrodes, has a structure in which the electrode assembly is impregnated with a nonaqueous electrolyte, and has an arrangement in which a plurality of grooves are formed in the formation surface of the positive electrode active material layer of the positive electrode such that the end portions of these grooves open at the edges of the positive electrode active material layer, these grooves are formed at a frequency of 1 to 10 grooves per 1 as a length in the positive electrode active material layer, and the sectional area of the grooves accounts for a ratio of 1 to 20% of the sectional area of the positive electrode active material layer.
  • this arrangement it is possible to obtain a high-dens
  • LiCoO 2 having an average particle diameter of 10 ⁇ m as a positive electrode active material
  • 2.5 parts by weight of graphite as a conductive material 2.5 parts by weight of acetylene black
  • This mixture and 3.5 parts by weight of polyvinylidene fluoride were kneaded to prepare a positive mix slurry.
  • One surface of a 15- ⁇ m-thick piece of aluminum foil as a current collector was coated with this slurry, and the slurry was dried.
  • the other surface of the aluminum foil was also coated with the slurry, and the slurry was dried, thereby forming positive electrode active material layers on the two surfaces of the aluminum foil.
  • the aluminum foil on the two surfaces of which the positive electrode active material layers were formed was molded into a predetermined thickness by roll press, thereby forming a band-like positive electrode having the positive electrode active material layers having a density of 3.2 g/cm 3 on its two surfaces.
  • this band-like positive electrode was passed between engraved emboss rolls to form a plurality of linear grooves having an inverted trapezoidal sectional shape in the positive electrode active material layers on the two surfaces of the positive electrode.
  • the plurality of grooves having an inverted trapezoidal sectional shape inclined to make an angle of 60° with the longitudinal direction of the positive electrode, and the frequency of these grooves was 8 grooves/mm.
  • the grooves having an inverted trapezoidal sectional shape formed in the two surfaces were inverted to cross each other when seen through one surface as shown in FIG. 9 mentioned earlier.
  • the ratio occupied by the sectional area of the grooves in the sectional area of the positive electrode active material layer was found to be 5% by sectional observation of the positive electrode.
  • Mesophase frequency-based carbon fibers were graphitized in an argon gas ambient at 3,000°C, and heat-treated in a chlorine gas ambient at 2,400°C, thereby synthesizing a graphitized carbon powder. Then, 100 parts by weight of the graphitized carbon powder and an N-methyl-2-pyrollidone solution in which 5 parts by weight of polyvinylidene fluoride were dissolved were mixed to prepare a negative mix slurry. The two surfaces of a 12- ⁇ m-thick piece of copper foil as a current collector were coated with this slurry, and the slurry was dried. After that, roll pressing was performed to form a band-like negative electrode having negative electrode active material layers having a density of 1.5 g/cm 3 on its two surfaces.
  • a nonaqueous electrolyte was prepared by dissolving 1.2 mols/L of LiPF 6 in a nonaqueous solvent mixture in which propylene carbonate, ethylene carbonate, and methyl ethyl carbonate were mixed at a volume ratio of 2 : 3 : 1.
  • Aluminum ribbon as a current collector tab was ultrasonically welded to a predetermined position of the positive electrode. Also, a polyimide protection tape for preventing a short circuit was made of adhere to the welded portion of the negative electrode. These positive and negative electrodes were wound via a separator made of a porous polypropylene film, thereby forming a cylindrical electrode assembly.
  • the electrode assembly and nonaqueous electrolyte were accommodated in a closed-end, cylindrical outer packaging can made of a metal, and a sealing plate made of an insulating material and having a positive terminal was airtightly attached to the opening of this outer packaging can.
  • a cylindrical lithium ion secondary battery having the structure shown in FIG. 1 described earlier was assembled by electrically connecting the current collector tag of the positive electrode of the electrode assembly to the positive terminal.
  • the plurality of linear grooves having an inverted trapezoidal sectional shape inclined to make an angle of 60° with the longitudinal direction of the positive electrode, and the frequency of these grooves was 8 grooves/mm. Note that these grooves formed in the two surfaces were inverted to cross each other when seen through one surface as shown in FIG. 9 mentioned earlier. Note also that the ratios occupied by the sectional areas of the grooves in the sectional areas of the positive electrode active material layers were found to be 1%, 2%, 15%, and 20% by sectional observation of the positive electrodes.
  • Three cylindrical lithium ion secondary batteries having the structure shown in FIG. 1 described earlier were assembled following the same procedure as in Example 1 except that the positive electrodes as described above were used.
  • the plurality of curved grooves having an inverted trapezoidal sectional shape inclined to make an angle of 60° with the longitudinal direction of the positive electrode, and the frequency of these grooves was 8 grooves/mm. Note that these grooves formed in the two surfaces were inverted to cross each other when seen through one surface. Note also that the ratios occupied by the sectional areas of the grooves in the sectional areas of the positive electrode active material layers were found to be 1%, 2%, 5%, 15%, and 20% by sectional observation of the positive electrodes.
  • Three cylindrical lithium ion secondary batteries having the structure shown in FIG. 1 described earlier were assembled following the same procedure as in Example 1 except that the positive electrodes as described above were used.
  • a band-like positive electrode having positive electrode active material layers having a density of 3.0 g/cm 3 on its two surfaces was formed following the same procedure as in Example 1. This positive electrode was passed through engraved emboss rolls to form a plurality of grooves in the positive electrode active material layers on the two surfaces of the positive electrode.
  • the plurality of linear grooves having an inverted trapezoidal sectional shape inclined to make an angle of 60° with the longitudinal direction of the positive electrode, and the frequency of these grooves was 8 grooves/mm. Note that these grooves formed in the two surfaces were inverted to cross each other when seen through one surface as shown in FIG. 9 mentioned earlier. Note also that the ratio occupied by the sectional area of the grooves in the sectional area of the positive electrode active material layer was found to be 5% by sectional observation of the positive electrode.
  • a cylindrical lithium ion secondary battery having the structure shown in FIG. 1 described earlier was assembled following the same procedure as in Example 1 except that the positive electrode as described above was used.
  • a positive electrode having a density of 3.2 g/cm 3 was formed following the same procedure as in Example 1.
  • a cylindrical lithium ion secondary battery having the structure shown in FIG. 1 described earlier was assembled following the same procedure as in Example 1 except that this positive electrode (a positive electrode having no grooves) was used.
  • the plurality of linear grooves having an inverted trapezoidal sectional shape inclined to make an angle of 60° with the longitudinal direction of the positive electrode, and the frequency of these grooves was 8 grooves/mm. Note that these grooves formed in the two surfaces were inverted to cross each other when seen through one surface as shown in FIG. 9 mentioned earlier. Note also that the ratios occupied by the sectional areas of the grooves in the sectional areas of the positive electrode active material layers were found to be 0.5% and 25%, which fell outside the range (1 to 20%) of the present invention, by sectional observation of the positive electrodes.
  • these grooves formed in the two surfaces were inverted to cross each other when seen through one surface as shown in FIG. 9 mentioned earlier.
  • the ratio occupied by the sectional area of the grooves in the sectional area of the positive electrode active material layer of each positive electrode was found to be 5% by sectional observation of the positive electrode.
  • a band-like positive electrode having positive electrode active material layers having a density of 2.8 g/cm 3 on its two surfaces was formed following the same procedure as in Example 1. This positive electrode was passed through engraved emboss rolls to form a plurality of grooves in the positive electrode active material layers on the two surfaces of the positive electrode.
  • the plurality of linear grooves having an inverted trapezoidal sectional shape inclined to make an angle of 60° with the longitudinal direction of the positive electrode, and the frequency of these grooves was 8 grooves/mm. Note that these grooves formed in the two surfaces were inverted to cross each other when seen through one surface. Note also that the ratio occupied by the sectional area of the grooves in the sectional area of the positive electrode active material layer was found to be 5% by sectional observation of the positive electrode.
  • a cylindrical lithium ion secondary battery having the structure shown in FIG. 1 described earlier was assembled following the same procedure as in Example 1 except that the positive electrode as described above was used.
  • Tables 1 to 4 show the multiple (specific surface area of positive electrode active material layer/specific surface area of negative electrode active material layer) of the specific surface area per unit area of the positive electrode active material layer of the positive electrode to the specific surface area per unit area of the negative electrode active material layer of the negative electrode which opposed the positive electrode with the separator sandwiched between them in the secondary battery of each of Examples 1 to 17 and Comparative Examples 1 to 6.
  • Example 1 Positive electrode density (g/cm 3 ) Groove pattern Groove frequency (number/mm) Sectional area of grooves (%) Example 1 3.2 Inclined and linear 8 5 Example 2 3.2 Inclined and linear 8 1 Example 3 3.2 Inclined and linear 8 2 Example 4 3.2 Inclined and linear 8 15 Example 5 3.2 Inclined and linear 8 20 Example 6 3.2 Inclined and linear 1 5 Example 7 3.2 Inclined and linear 4 5 Example 8 3.2 Inclined and linear 10 5 Example 9 3.2 Inclined and curved 8 1 Example 10 3.2 Inclined and curved 8 2 Example 11 3.2 Inclined and curved 8 5 Example 12 3.2 Inclined and curved 8 15 Example 13 3.2 Inclined and curved 8 20 Table 2 Multiple of specific surface area of positive electrode to negative electrode Number of charge/discharge cycles Example 1 0.60 100 Example 2 0.56 96 Example 3 0.57 97 Example 4 0.80 103 Example 5 0.95 107 Example 6 0.55 96 Example 7 0.57 98 Example 8 0.62 102 Example 9 0.
  • the plurality of linear grooves having an inverted trapezoidal sectional shape inclined to make angles of 45° and 75° with the longitudinal direction of each positive electrodes, the frequency of these grooves was 8 grooves/mm, and the ratio occupied by the sectional area of the grooves in the sectional area of the positive electrode active material layer was 5%. Note that these grooves formed in the two surfaces were inverted to cross each other when seen through one surface as shown in FIG. 9 mentioned earlier.
  • the battery characteristics (charge/discharge cycle characteristics) of the assembled cylindrical lithium ion secondary batteries of Examples 18 and 19 were evaluated by the same method as in Example 1. The results are shown in Tables 5 and 6 below. Note that Tables 5 and 6 also show the multiple (specific surface area of positive electrode active material layer/specific surface area of negative electrode active material layer) of the specific surface area per unit area of the positive electrode active material layer of the positive electrode to the specific surface area per unit area of the negative electrode active material layer of the negative electrode which opposed the positive electrode with the separated sandwiched between them in the secondary battery of each of Examples 18 and 19. Note also that the evaluation results of the secondary battery of Example 1 are also shown.

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